CN112469752A - 泡沫组合物和由其制成的泡沫复合材料 - Google Patents
泡沫组合物和由其制成的泡沫复合材料 Download PDFInfo
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Abstract
一种形成硬质泡沫的组合物,其包含:(a)至少一种异氰酸酯组分;(b)至少一种多元醇组分;(c)至少一种发泡剂;(d)至少一种催化剂;(e)至少一种表面活性剂;以及(f)至少一种硅烷组分。所述形成泡沫的组合物提供的泡沫在粘附到衬底时,粘附力有所增加。所述形成泡沫的组合物可以特别适于制造包含安置在第一覆面材料与第二覆面材料之间的泡沫芯的板结构。
Description
技术领域
本发明涉及一种形成泡沫的组合物和由此类形成泡沫的组合物制成的泡沫复合材料。
背景技术
已知的板系统通常是由如硬质泡沫等硬质泡沫材料的芯制成的复合材料,所述芯夹置在两个衬底(例如,金属,如铝、钢或箔;纸;塑料;复合材料等)之间。板的衬底通常被称为覆面(或面层)材料。迄今为止,由于芯硬质泡沫与覆面(或面层)材料之间的粘附力差或不足,因此众所周知,用于制备(连续或不连续)板系统的已知的形成硬质泡沫的调配物表现出耐久性问题。
令人期望的是提供一种用于产生泡沫的形成泡沫的组合物(或调配物或系统),所述形成泡沫的组合物可以以一步法原位调配并且可以具有对复合产品的面层材料增加的粘附力。
发明内容
本发明涉及一种组成形成泡沫的调配物的所有组分的单个组合的硬质泡沫调配物。在一个实施例中,本发明包含可用于制备板的芯泡沫的硬质泡沫调配物。形成泡沫的调配物表现出改善的面层粘合性质,所述面层粘合性质可以通过将硅烷添加剂包含在形成泡沫的调配物的A侧中来实现。本发明包含选择硅烷添加剂以及将硅烷添加剂掺入调配物的A侧中以改善泡沫芯对复合产品的面层材料的粘附力。在一个优选实施例中,硅烷添加剂可以是例如异氰酸基硅烷化合物。
在一个一般实施例中,本发明的形成硬质泡沫的组合物包含:(a)至少一种异氰酸酯组分;(b)至少一种多元醇组分;(c)至少一种发泡剂;(d)至少一种催化剂;(e)至少一种表面活性剂;以及(f)至少一种硅烷组分。有利地,具有硅烷组分(f)的形成泡沫的组合物可用于提供的泡沫的粘附力(如通过ASTM D-1623的方法所测得)比不具有硅烷组分(f)的形成泡沫的组合物提供的泡沫的粘附力至少大(>)10%(%)。
本发明的另一个实施例包含用于制备上述形成泡沫的组合物的方法。
本发明的仍另一个实施例包含如板等复合制品,所述复合制品包括例如两个壳板(例如,金属板)和安置在所述两个壳板之间的泡沫芯,其中芯泡沫由具有对所述两个壳板增加的粘附力的上述形成泡沫的组合物制成。
具体实施方式
形成泡沫的调配物有利地用于产生聚氨酯硬质(PUR)泡沫和聚异氰脲酸酯硬质(PIR)泡沫。通常,泡沫是通过使形成泡沫的反应性组合物、调配物或系统反应来制作的,所述组合物、所述调配物或所述系统包含包括一种或多种聚异氰酸酯化合物的聚异氰酸酯组分(a)与包括一种或多种多元醇化合物的多元醇组分(b)的反应。优选地,所述反应在存在如美国专利第7,714,030号中描述的(c)一种或多种发泡剂和(d)一种或多种催化剂的情况下执行。当上述组分(a)-(d)混合并反应时,所述反应形成泡沫。
本发明的泡沫系统包含用于制备如PUR泡沫或PIR泡沫等硬质泡沫的形成泡沫的组合物。在本发明中,形成泡沫的反应性组合物包含掺入作为组分(f)的硅烷添加剂,以增加泡沫产品与一种或多种衬底的粘附力。调配物中的硅烷添加剂增加了由形成泡沫的组合物或调配物制成的泡沫芯与复合产品的面层材料之间的粘附力。例如,在一个优选实施例中,硅烷添加剂可以是异氰酸基硅烷化合物。
本发明的形成PUR或PIR泡沫的组合物或调配物包含至少一种异氰酸酯组分,作为调配物的组分(a),即,可用于本发明中的异氰酸酯组分可以包含一种或多种含异氰酸酯的组分。可用于制备形成泡沫的组合物的聚异氰酸酯组分,即组分(a)可以包含例如单一的聚异氰酸酯化合物或两种或更多种不同的聚异氰酸酯化合物的混合物;并且异氰酸酯组分(a)化合物适用于与多元醇组分(b)反应。
通常,可用于本发明中的聚异氰酸酯组分(a)的合适的聚异氰酸酯化合物可以包含芳香族聚异氰酸酯、脂肪族聚异氰酸酯和脂环族聚异氰酸酯。例如,可用于制备形成硬质泡沫的组合物的聚异氰酸酯组分,即组分(a)可以包含一种或多种聚异氰酸酯化合物或异氰酸酯封端的预聚物,如间苯二异氰酸酯;2,4-和/或2,6-甲苯二异氰酸酯(TDI);二苯基甲烷二异氰酸酯(MDI)的各种异构体;所谓的聚合MDI产物;碳二亚胺改性的MDI产物;六亚甲基-1,6-二异氰酸酯;四亚甲基-1,4-二异氰酸酯;环己烷-1,4-二异氰酸酯;六氢甲苯二异氰酸酯;氢化MDI;萘-1,5-二异氰酸酯;以及其混合物。
聚异氰酸酯组分(a)的平均异氰酸酯基官能度在一个实施例中可以例如大于或等于(≥)2.3,在另一个实施例中≥2.7,并且在仍另一个实施例中为2.5到4.0。
通常,本发明的形成泡沫的调配物中使用的聚异氰酸酯组分(a)的量的异氰酸酯指数通常可以为例如100到800。“异氰酸酯指数”意指反应混合物中的异氰酸酯基与活性氢原子的当量之比乘以100。换句话说,异氰酸酯指数是异氰酸酯(NCO)基的摩尔当量除以调配物中存在的异氰酸酯反应性氢原子的总摩尔当量乘以100。如本领域的普通技术人员将理解的,可以通过至少一种异氰酸酯组分提供异氰酸酯基,并且可以通过至少一种多元醇组分提供活性氢原子。
当制备PUR泡沫时,异氰酸酯指数在一个实施例中可以为100到180,并且在另一个实施例中可以为110到140。当制备PIR泡沫时,异氰酸酯指数在一个实施例中可以为200到800,并且在另一个实施例中可以为200到600。可替代地,聚异氰酸酯组分可以表示整个泡沫调配物的30重量%(wt%)到90wt%,并且优选地40wt%到80wt%。
可用于制备形成泡沫的组合物的多元醇组分,即组分(b)可以包含例如单一的多元醇化合物或两种或更多种不同的多元醇化合物的混合物。例如,可用于制备形成泡沫的组合物的多元醇组分,即组分(b)可以包含如以下等本领域已知的一种或多种多元醇化合物:亚烷基二醇,如乙二醇、丙二醇、1,4-丁二醇、1,6-己二醇等和其混合物;二醇醚,如二乙二醇、三乙二醇等和其混合物;含叔胺的多元醇;聚醚多元醇;芳香族聚酯多元醇;以及其混合物。对于多元醇组分还有用的是可以包含聚酯多元醇/聚醚多元醇共混物。可用于共混物的聚酯的实例可以包含256、2352、2031及其混合物。可用于共混物的聚醚的实例可以包含VORANOLTM360、VORANOLTM2070、VORANOLTMRN-482及其混合物。
在一个实施例中,多元醇组分的官能度(异氰酸酯反应性基团/分子的平均数量)可以例如为2到8。通常,形成泡沫的调配物的羟基当量(HEW)在一个实施例中可以例如小于(<)600,在另一个实施例中小于<400,并且在仍另一个实施例中<250。在又其它实施例中,调配物的HEW可以为10到<600。多元醇可以表示整个泡沫调配物的10wt%到70wt%,并且优选地20wt%到60wt%。
各种常规的发泡剂可以用作本发明的组分(c)。可用于制备形成泡沫的组合物的发泡剂,即组分(c)可以包含例如单个的发泡剂化合物或两种或更多种不同的发泡剂化合物的混合物。例如,可用于制备形成泡沫的组合物的发泡剂,即组分(c)可以包含水、各种烃、各种氢氟烃、各种氯氟烃、各种氟烃、各种氯烃、各种氢卤代烯烃(如氢氟烯烃和氢氯氟烯烃)、各种酯、各种醚、各种酮、各种醛,在发泡反应条件下产生氮气或二氧化碳的各种化学发泡剂等;以及其混合物中的一种或多种。在一个优选实施例中,水可以用作发泡剂。
可以将发泡剂,即组分(c)添加到聚异氰酸酯组分(a)或多元醇组分(b)或组分(a)和(b)两者中。在一个优选实施例中,例如,将发泡剂添加到多元醇组分中。在本发明的形成泡沫的调配物中使用的发泡剂,即组分(c)的重量百分比的量在一个实施例中在多元醇组分侧中通常可以在0.01wt%到20wt%的范围内并且在另一个实施例中在多元醇组分侧中可以在5wt%到10wt%的范围内。可替代地,发泡剂可以表示整个泡沫调配物的0.01wt%到15wt%,并且优选地1wt%到10wt%。
各种已知的催化剂可以用作本发明中的组分(d)。可用于制备形成泡沫的组合物的催化剂,即组分(d)可以包含例如单个的催化剂化合物或两种或更多种不同的催化剂化合物的混合物。例如,可用于本发明中的催化剂可以包含:叔胺,如三甲胺、三乙胺、N-甲基吗啉、N-乙基吗啉、N,N-二甲基苄胺、N,N-二甲基乙醇胺、N,N,N',N'-四甲基-1,4-丁二胺、N,N-二甲基哌嗪、双(二甲基氨基乙基)醚和三亚乙基二胺;叔膦,如三烷基膦和二烷基苄基膦(dialkylbenzylphosphine);各种碱金属羧酸盐,如辛酸钾、乙酸钾、新戊酸钾等;以及其混合物。在仍另一个实施例中,叔胺催化剂,如N,N,N-三甲基-N-羟乙基-双(氨基乙基)醚、二甲基1-2(2-氨基乙氧基)乙醇等;以及其混合物也可以用于本发明。
可以将催化剂,即组分(d)与形成泡沫的组合物的其它组分混合;并且在一个优选实施例中,例如,可以将催化剂添加到多元醇组分中。在泡沫调配物中使用的催化剂,即组分(d)的重量百分比的量在一个实施例中在多元醇组分侧中通常可以在0.01wt%到10wt%的范围内并且在另一个实施例中在多元醇组分侧中可以在0.5wt%到2.5wt%的范围内。可替代地,催化剂可以表示整个泡沫调配物的0.001wt%到5wt%,并且优选地0.01wt%到3wt%。
可用于制备形成泡沫的组合物的表面活性剂,即组分(e)可以包含例如单个的表面活性剂化合物或两种或更多种不同的表面活性剂化合物的混合物。表面活性剂是用于帮助使起始材料均质化的有益化合物并且还可以适于调节泡沫的泡孔结构。可以添加包含硅酮类表面活性剂和有机表面活性剂的表面活性剂,以用作泡孔稳定剂。
可用于本发明中的一些代表性的硅酮类表面活性剂材料可以包含例如聚硅氧烷聚氧化烯嵌段共聚物和硅酮聚醚(SPE)表面活性剂。可用于本发明中的一些代表性的有机表面活性剂材料可以包含例如含有聚氧乙烯-聚氧丁烯嵌段共聚物的有机表面活性剂。可用于本发明中的其它表面活性剂包含长链醇的聚乙二醇醚、长链烯丙酸硫酸酯、烷基磺酸酯、烷基芳基磺酸的叔胺或链烷醇胺盐及其组合。在另一个实施例中,有机表面活性剂如可购自陶氏化学公司(The Dow Chemical Company)获得的VORASURFTM504可以在本发明中使用。
在一个实施例中,可以将表面活性剂,即组分(e)掺入形成泡沫的调配物的B侧中(即,掺入多元醇组分(b));并且基于形成泡沫的组合物中的总组分,表面活性剂添加剂的浓度在一个实施例中可以为例如0.01wt%到5wt%,在另一个实施例中为0.1wt%到3wt%,并且在仍另一个实施例中为0.5wt%到2wt%。
可用于制备形成泡沫的组合物的硅烷添加剂,即组分(f)可以包含例如单个的硅烷化合物或两种或更多种不同的硅烷化合物的混合物。期望的硅烷可以被定义为中心硅(Si)原子与至少一个烷氧基和至少一个异氰酸酯官能化的部分共价连接(或相邻)的物种,如以下结构中表示的:
其中在以上结构中,R1为烷氧基,并且所述分子可以具有1到3个此类具有不同大小/长度的基团(例如,C1-C12);R2为烷基或氢,并且所述分子可以具有0到2个此类具有不同大小/长度的基团(例如,C1-C12);R3为异氰酸酯封端的/官能化的部分,并且所述分子可以具有1到3个此类具有不同大小/长度的基团(例如,C0-C12);并且X为不与异氰酸酯反应的任何其它物种。
例如,可用于制备形成泡沫的组合物的硅烷组分,即组分(f)可以包含本领域已知的一种或多种硅烷化合物,如γ-异氰酸基丙基三乙氧基硅烷或γ-异氰酸基丙基三甲氧基硅烷;以及其混合物。在一个优选实施例中,可以将硅烷,即组分(f)添加到聚异氰酸酯组分(a)中。
在一个实施例中,可以将硅烷,即组分(f)掺入形成泡沫的调配物的A侧中;并且硅烷添加剂的浓度在调配物的聚异氰酸酯组分中可以为例如>0.01wt%,在另一个实施例中为0.02wt%到5wt%,并且在仍另一个实施例中为0.05wt%到1wt%。可替代地,硅烷在一个实施例中可以表示整个泡沫调配物的0.001wt%到5wt%,并且在另一个实施例中表示0.01wt%到1wt%。
可以将各种其它任选常规组分添加到聚异氰酸酯组分(a)和/或多元醇组分(b)中以形成泡沫系统。可用于泡沫系统的合适的任选化合物或添加剂是本领域公知的并且可以包含例如其它助催化剂、增韧剂、流动改性剂、染料、稀释剂、稳定剂、增塑剂、催化剂减活剂、阻燃剂、液体成核剂、固体成核剂、奥斯特瓦尔德(Ostwald)成熟延迟添加剂及其混合物。在一个优选实施例中,本发明的组合物可以包含一种或多种阻燃剂。
可以执行上述任选添加剂和添加剂量的任何合适的组合,以及将一种或多种任选添加剂掺入形成泡沫的组合物中的方法。通常,如果将上述任选添加剂中的每种添加剂用于泡沫组合物中,则按组合物总重量计,所述每种添加剂不超过15wt%。任选添加剂在一个实施例中可以通常有利地在0wt%到15wt%的范围内使用;并且在另一个实施例中在0.001wt%到10wt%的范围内使用。
作为本发明形成泡沫的组合物的一个说明,所述组合物包含:(a)至少一种异氰酸酯组分,所述至少一种异氰酸酯组分的异氰酸酯基的平均官能度为2.5到4.0;(b)至少一种多元醇组分,所述至少一种多元醇组分的羟基当量小于600;(c)存在于组合物中的至少一种发泡剂,所述至少一种发泡剂的浓度在组合物的多元醇组分侧中为0.01wt%到20wt%;(d)至少一种催化剂,所述至少一种催化剂的浓度在组合物的多元醇组分侧中为0.01wt%到5wt%;(e)至少一种表面活性剂,所述至少一种表面活性剂的浓度在组合物的多元醇组分侧中为0.01wt%到5wt%;以及(f)至少一种硅烷组分,所述至少一种硅烷组分的浓度在组合物的聚异氰酸酯组分侧中为0.01wt%到5wt%。
在一个广义的实施例中,用于制作本发明的反应性泡沫组合物的方法包含通常以组分的单个组合将如上所述的组分(a)到(f)以一锅法混合以形成泡沫组合物。可替代地,泡沫组合物的制备包含:提供至少一种聚异氰酸酯组分(a),所述至少一种聚异氰酸酯组分在本文中也可以被称为泡沫组合物的“A侧”;以及提供至少一种多元醇组分(b),所述至少一种多元醇组分在本文中也可以被称为泡沫组合物的“B侧”。
在一个实施例中,可以将发泡剂组分(c)和硅烷组分(f)添加到泡沫调配物的A侧中;并且可以将发泡剂组分(c)、催化剂组分(d)、表面活性剂组分(e)和任选添加剂中的任何添加剂添加到泡沫调配物的B侧中。
在制备泡沫组合物时,用成分(a)-(f)和其它任选成分(如果有的话)分别且单独地制备A侧和B侧;并且可以将所有组分以上文讨论的期望浓度混合在一起以制备泡沫组合物。在一个优选实施例中,A侧可以是至少一种异氰酸酯组分和至少一种硅烷组分的预混合物以形成所述预混合物;并且B侧可以是至少一种多元醇组分、至少一种发泡剂、至少一种催化剂和至少一种表面活性剂的预混合物。预混合成分以形成A侧可以例如通过以下执行:在环境条件下通过静态混合器或在容器中在线组合不同组分,并通过再循环或用叶轮进行混合。类似地,预混合成分以形成B侧可以例如通过以下执行:通过静态混合器或在环境条件下在容器中,利用通过再循环或用叶轮混合来在线组合不同组分。
一旦如上所述形成A侧和B侧的预混合物,就可以在一个实施例中在65℉到100℉(18℃到38℃)的温度下通过A侧和B侧使组分混合;并且在另一个实施例中在70℉到95℉(21℃到35℃)温度下使组分混合。可以通过任何已知的混合工艺和设备将组成泡沫组合物的成分混合在一起。例如,可以通过任何已知的尿烷发泡设备将聚异氰酸酯组分预混合物(A侧)和多元醇预混合物(B侧)混合在一起。在一个广义的实施例中,一种用于制作硬质泡沫的方法包含使如借助于A侧和B侧引入的组分组分(a)和(b)混合并反应,其中A侧和/或B侧可以包含组分(c)-(f)以及如上所述的任何数量的其它任选组分或添加剂。
为了制造硬质泡沫,可以在优选地环境温度下并且以期望的比例通过碰撞混合或使两种流体组分通过静态混合器而将A侧与B侧混合,从而形成反应性调配物。所得反应性共混物然后经历足以允许发生发泡反应以形成泡沫的条件,如高温。通常,可以将形成泡沫的反应性调配物注入或倒入含有面层的壳或板的模腔中,随后以预定的温度在模具中加热调配物并持续期望的时间量以使泡沫固化。
例如,一旦组分通过A侧和B侧的混合物彼此紧密接触地结合在一起,则形成泡沫的调配物在一个实施例中可以在85℉到140℉(29℃到60℃)的温度下加热;在另一个实施例中在95℉到130℉(35℃到54℃)的温度下加热;并且在仍另一个实施例中在105℉到125℉(40℃到52℃)的温度下加热。熟练的技术人员可以调整本发明的反应动力学,以实现最好的模具填充和发泡,从而实现最经济的制造。
根据本发明生产的泡沫具有某些有利的性质和益处。例如,在将硅烷组分(f)添加到形成泡沫的调配物中的情况下制作的泡沫可以显示出对面层材料的粘附力比在不将硅烷组分(f)添加到形成泡沫的调配物中的情况下制作的泡沫显示出对面层材料的粘附力大1.5倍到2倍。在一个一般的实施例中,具有硅烷组分(f)的形成泡沫的组合物提供的泡沫的粘附力比不具有硅烷组分(f)的形成泡沫的组合物提供的泡沫的粘附力至少大例如10%。在另一个一般的实施例中,具有硅烷组分(f)的形成泡沫的组合物提供的泡沫的粘附力比不具有硅烷组分(f)的形成泡沫的组合物提供的泡沫的粘附力至少大例如50%。增加的粘附力百分比可以通过ASTM D-1623的方法来测量。
泡沫的其它性质可以通过许多性质测试来测量,以提供对增加的粘附力的指示,例如包含根据ASTM D-1623中描述的程序以0.05英寸/分钟(in/min)(0.02毫米/秒(mm/s))的测试速度测量的泡沫和面层材料的拉伸粘合强度;以及如根据ASTM D-1621中描述的方法测定的泡沫面层组合件上的应变载荷、泡沫面层组合件的断裂载荷以及泡沫的抗压强度。例如,在一般的实施例中,泡沫的拉伸粘合强度可以为>10磅每平方英寸(psi)或>69千帕(kPa);泡沫的应变载荷可以为>10%(%);泡沫的断裂载荷可以为>200磅力(lbf)或>890牛顿(N);并且泡沫的抗压强度可以为>15psi或>103.4kPa。
通常,由本发明的调配物生产的硬质泡沫包含在一个实施例中具有如根据ASTMD-1622测定的芯密度为1.5磅每立方英尺(pcf)到3.5pcf(24.0千克每立方米(kg/m3)到56kg/m3)的泡沫,在另一个实施例中为1.8pcf到2.5pcf(28.8kg/m3到40.0kg/m3)的泡沫,并且在仍另一个实施例中为2.0pcf到2.3pcf(32.0kg/m3到36.8kg/m3)的泡沫。
泡沫指数在一个实施例中通常可以为100到800并且在另一个实施例中为100到180或200到600。
如前所述,通过提供夹置在两种面层材料之间的PUR或PIR泡沫的芯来制造本发明的板复合制品。可以使用公知的分批法或连续法中的任何方法和辅助设备来形成泡沫复合制品。例如,可以由本发明的形成泡沫的调配物通过将调配物倒入含有面层材料的模腔中,随后在具有面层材料的加热模具中使调配物固化来生产泡沫芯。在一个实施例中,制作板结构的方法通常包含以下步骤:例如,将面层材料置入模具中,将形成泡沫的组合物倒入模具中,关闭模具,并且然后使形成泡沫的组合物上升并反应以填充与面层材料接触的模具,从而产生复合结构。在另一个实施例中,可以通过将发泡混合物注入粘附有面层材料的预组装模具中来制备复合材料。在仍另一个实施例中,可以通过在连续层压机上在两层面层材料,即第一层面层材料与第二层面层材料之间分配发泡混合物来制备复合材料。还可以使用本领域已知的用于制造泡沫复合产品的其它常规成型技术。
可用于本发明中的面层材料可以是衬底材料,例如金属,如铝、钢或箔;纸;塑料;复合材料;等;或其组合。在一个优选实施例中,复合材料可以包含夹置在第一面层材料与第二面层材料之间的泡沫芯,其中第一覆面材料是铝衬底,并且第二覆面材料也是铝衬底。
在一个优选实施例中,本发明的用于制作板复合结构的方法包含以下步骤:(I)提供具有安置在模具中的面层材料的模具;(II)提供形成泡沫的反应性混合物;(III)将形成泡沫的反应性混合物倒入模具中以接触面层材料结构;(IV)使形成泡沫的反应性混合物在预定的时间段和条件下反应,以在模具内部形成泡沫芯复合结构;以及(V)从模具中除去所得复合结构。
可以通过A侧流和B侧流的碰撞混合并且在>1,000psi(6.9MPa)、优选地>1,200psi(8.3MPa)并且更优选地≥1,500psi(≥10.3MPa)的液体压力下制备发泡混合物。液体温度的范围在一个实施例中可以为65℉到90℉(18℃到32℃)并且在另一个实施例中为70℉到85℉(21℃到29℃)。所需的材料量可以取决于目标密度和要填充的腔的体积,所述目标密度和体积是本领域的技术人员可以容易测定的参数。
根据本发明制作的复合产品可以用于各种应用中,所述应用包含例如用于生产内墙板和外墙板,步入式冷却器组合件等。
实例
提供以下实例以进一步详细地说明本发明,但不应解释为限制权利要求的范围。除非另有说明,否则所有份数和百分比均按重量计。
本文在以下表I中描述了在本发明实例(Inv.Ex.)和随后的比较实例(Comp.Ex.)中使用的各种原材料(成分或组分)。
表I——原材料
用于制备调配物以及粘附力测试测量的一般程序
为了证明硬质泡沫芯与板复合材料中的面层材料之间的粘附力得到改善,首先将A侧和B侧组分预混合/预共混,之后填充到高压发泡机的相应槽中。然后通过以1,500psi(10.3MPa)碰撞高压发泡机来混合组分中的所有组分,其中液体保持在大约(约)70℉(约21℃)并分配到40厘米(cm)×70cm×10cm加热(在125℉(51.7℃)的温度下)的板模具中,所述板模具安装有形成模具底部的内衬的铝衬底。将板孵育40分钟(min),然后脱模,并且然后在环境条件下(约77℉(25℃))以完成固化。
为了测试粘附力,将具有铝面层的泡沫的多个(至少四个)区段从固化板上切成4英寸(10cm)×4英寸(10cm)×2英寸(5cm)的大小。然后根据ASTM D-1623中描述的程序,针对区段中的每个区段测量泡沫与面层拉伸粘合强度。ASTM D-1623的方法中使用的测试速度为0.05英寸/分钟(0.02毫米/秒)。下表II中示出每种测试调配物的测量拉伸粘合强度、应变和断裂载荷。根据ASTM D-1621中描述的方法测定抗压强度。
表II——调配物
表II的注释:表II中描述的调配物的量以“pphp(每百份多元醇的份数)”为单位。
Claims (11)
1.一种形成硬质泡沫的组合物,所述组合物包括:
(a)至少一种异氰酸酯组分;
(b)至少一种多元醇组分;
(c)至少一种发泡剂;
(d)至少一种催化剂;
(e)至少一种表面活性剂;以及
(f)至少一种硅烷组分。
2.根据权利要求1所述的组合物,其中所述至少一种异氰酸酯组分和所述至少一种硅烷组分是预混合的。
3.根据权利要求1所述的组合物,其中如通过ASTM D-1623的方法所测量的,具有硅烷组分(f)的所述形成泡沫的组合物提供的泡沫的粘附力比不具有所述硅烷组分(f)的形成泡沫的组合物提供的泡沫的粘附力大至少10%。
5.根据权利要求1所述的组合物,其中所述至少一种硅烷组分是γ-异氰酸基丙基三乙氧基硅烷;γ-异氰酸基丙基三甲氧基硅烷;或其混合物。
6.根据权利要求1所述的形成泡沫的组合物,其中(a)所述至少一种异氰酸酯组分的异氰酸酯基的平均官能度为2.5到4.0;(b)所述至少一种多元醇组分的羟基当量小于600;(c)存在于所述组合物中的所述至少一种发泡剂的浓度在所述组合物的多元醇组分侧中为0.01重量%到20重量%;(d)所述至少一种催化剂的浓度在所述组合物的多元醇组分侧中为0.01重量%到5重量%;(e)所述至少一种表面活性剂的浓度在所述组合物的多元醇组分侧中为0.01重量%到5重量%;并且(f)所述至少一种硅烷组分的浓度为聚异氰酸酯组分侧的大于0.01重量%到5重量%。
7.一种硬质泡沫制品,其包括根据权利要求1到6中任一项所述的形成硬质泡沫的组合物的反应产物。
8.一种复合板结构,其包括:
(a)第一覆面材料;
(b)第二覆面材料;以及
(c)与所述第一覆面材料和所述第二覆面材料的表面的至少一部分接触的硬质泡沫;其中所述硬质泡沫夹置在所述第一覆面材料与所述第二覆面材料之间;并且其中所述硬质泡沫包括根据权利要求1到6中任一项所述的形成硬质泡沫的组合物的反应产物。
9.根据权利要求8所述的复合结构,其中所述第一覆面材料是金属衬底;并且其中所述第二覆面材料是金属衬底。
10.一种制作硬质泡沫板复合结构的方法,所述方法包括以下步骤:
(I)提供第一覆面材料;
(II)提供第二覆面材料;以及
(III)将根据权利要求1到6中任一项所述的形成硬质泡沫的组合物施涂到所述第一覆面材料和所述第二覆面材料的表面的至少一部分上;其中所述形成硬质泡沫的组合物施涂在所述第一覆面材料与所述第二覆面材料之间,使得形成夹置在所述第一覆面材料与所述第二覆面材料之间的泡沫芯。
11.一种形成根据权利要求1到6中任一项所述的形成硬质泡沫的组合物的方法,所述方法包括:(i)将所述至少一种异氰酸酯组分和所述至少一种硅烷组分混合以形成预混合物;以及(ii)向所述预混合物添加所述至少一种多元醇组分、所述至少一种发泡剂、所述至少一种催化剂以及所述至少一种表面活性剂。
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